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Prioritisation and Analysis of Faults in Shirt Production by the A3 Technique

Mehmet Küçük
Mehmet Küçük
   | 08 juin 2022
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Article Category: Research Article
Publié en ligne: 08 juin 2022
Pages: 35 - 46
DOI: https://doi.org/10.2478/ftee-2022-0005
Mots clés
© 2022 Mehmet Küçük, published by Sciendo
This work is licensed under the Creative Commons Attribution-NonCommercial-NoDerivatives 3.0 License.

Fig. 1

Faults of line-1 → Data obtained from Line-1 -Daily average checked quantity: 504 -Number of working days: 22 -Total number of controls during the working time: 11.088 -Total number of faults encountered: 640 -Fault type and frequency oStain à 224 oCollar Tip Form à 151 oCuff Form à 122 oButton hole à113 oOther à 30
Faults of line-1 → Data obtained from Line-1 -Daily average checked quantity: 504 -Number of working days: 22 -Total number of controls during the working time: 11.088 -Total number of faults encountered: 640 -Fault type and frequency oStain à 224 oCollar Tip Form à 151 oCuff Form à 122 oButton hole à113 oOther à 30

Fig. 2

Faults of line-2 → Data obtained from Line-2 -Daily average checked quantity: 1000 -Number of working days: 22 -Total number of controls during the working time: 22.000 -Total number of faults encountered: 1536 -Fault type and frequency oStain à 547 oCollar Tip Form à 430 oButton à 354 oCuff Form à 185 oOther à20
Faults of line-2 → Data obtained from Line-2 -Daily average checked quantity: 1000 -Number of working days: 22 -Total number of controls during the working time: 22.000 -Total number of faults encountered: 1536 -Fault type and frequency oStain à 547 oCollar Tip Form à 430 oButton à 354 oCuff Form à 185 oOther à20

Fig. 3

Faults of line-3 → Data obtained from Line-3 -Daily average checked quantity: 1200 -Number of working days: 22 -Total number of controls during the working time: 26.400 -Total number of faults encountered: 2115 -Fault type and frequency oCollar Tip Form à 570 oStitch fault à 468 oButton à 348 oCuff Form à 274 oPosition à 204 oOther à 251
Faults of line-3 → Data obtained from Line-3 -Daily average checked quantity: 1200 -Number of working days: 22 -Total number of controls during the working time: 26.400 -Total number of faults encountered: 2115 -Fault type and frequency oCollar Tip Form à 570 oStitch fault à 468 oButton à 348 oCuff Form à 274 oPosition à 204 oOther à 251

Fig. 4

Faults of line-4 → Data obtained from Line-4 -Daily average checked quantity: 950 -Number of working days: 22 -Total number of controls during the working time: 20.900 -Total number of faults encountered: 1210 -Fault type and frequency oStain à 374 oCollar Tip Form à 371 oCuff Form à 258 oInterlining Resin à 177 oOther à 30
Faults of line-4 → Data obtained from Line-4 -Daily average checked quantity: 950 -Number of working days: 22 -Total number of controls during the working time: 20.900 -Total number of faults encountered: 1210 -Fault type and frequency oStain à 374 oCollar Tip Form à 371 oCuff Form à 258 oInterlining Resin à 177 oOther à 30

Fig. 5

Faults of line-5 → Data obtained from Line-5 -Daily average checked quantity: 1000 -Number of working days: 22 -Total number of controls during the working time: 22.000 -Total number of faults encountered: 1974 -Fault type and frequency oCollar Tip Form à 681 oStain à 678 oCuff Form à 289 oButton à138 oFiber Flies à 101 oOther à 87
Faults of line-5 → Data obtained from Line-5 -Daily average checked quantity: 1000 -Number of working days: 22 -Total number of controls during the working time: 22.000 -Total number of faults encountered: 1974 -Fault type and frequency oCollar Tip Form à 681 oStain à 678 oCuff Form à 289 oButton à138 oFiber Flies à 101 oOther à 87

Fig. 6

Faults of line-6 → Data obtained from Line-6 -Daily average checked quantity: 1150 -Number of working days: 22 -Total number of controls during the working time: 25.300 -Total number of faults encountered: 1210 -Fault type and frequency oStain à 355 oCollar Tip Form à 247 oColour Difference à 231 oNeedle à 188 oOther à 189
Faults of line-6 → Data obtained from Line-6 -Daily average checked quantity: 1150 -Number of working days: 22 -Total number of controls during the working time: 25.300 -Total number of faults encountered: 1210 -Fault type and frequency oStain à 355 oCollar Tip Form à 247 oColour Difference à 231 oNeedle à 188 oOther à 189

Fig. 7

Pareto diagram of the faults
Pareto diagram of the faults

Fig. 8

Samples of 2nd quality collars
Samples of 2nd quality collars

Fig. 9

Collars manufactured with the apparatus
Collars manufactured with the apparatus

Fig. 10

Root cause analysis
Root cause analysis

Fig. 11

Cutting apparatus
Cutting apparatus

Fig. 12

Everting apparatus
Everting apparatus

Fig. 13

Collar automat [9]
Collar automat [9]

Records obtained by processes with the apparatus

Collar Forming Records
With the Apparatus
Taking a piece - putting under the needle Sewing Cutting (the seam allowance) Turn inside out - Forming the edges (with the apparatus) (2 Edges) Putting the piece away - taking another one
Sec R Sec R Sec R Sec R Sec R
Sample-1 3,6 95 11 100 8,1 105 18,4 100 1,2 100
Sample-2 3,2 100 11,2 110 7,5 105 18 100 1 100
Sample-3 3,5 100 10,8 105 9 100 17,5 100 1,5 95
Sample-4 3,6 95 10,9 105 7,3 100 17,7 95 1 100
Sample-5 3,4 95 11,5 100 8,7 90 18,2 100 1,5 95
Sample-6 3,4 100 11 100 9 90 18 100 1,4 95
Sample-7 2,6 115 10,7 100 9 100 17,9 95 1,3 100
Sample-8 4,2 90 10,8 100 8,7 90 17 95 1,2 100
Sample-9 3,7 100 11,5 95 8,8 100 17,8 95 1,4 95
Sample-10 3,9 100 10 110 9 100 19 90 1 100
Averages 3,5 99,0 10,9 102,5 8 5 18,0 97,0 1,3 98,0
Basic Time= Avg Time × Avg Rating 100 3,5 11,2 8,3 17,4 1,2
Total Basic Time 41,7
Relaxation Allowance (%4) 1,67
Unavoidable Delays (%7) 2,92
STANDARD TIME (sec) 46,2

The faults and effects

FAULT EXPLANATION EFFECT
1. Size difference A difference in the size of the pieces Repetition of the spreading-cutting processes
2. Barcode The attached barcode does not belong to the product. The delivery of the product to a different warehouse
3. Fabric Fault Defects on the fabric affect the quality of the product Disassemble process, repetition of the spreading-cutting processes
4. Button Broken, incorrect, unsewn or improper positioning of the buttons Disassemble process or re-sewing, productivity loss
5. Label Incorrect, defected or incorrect positioning Disassemble process and re-sewing, productivity loss
6. Needle Unsuitable needle for the fabric or the yarn Damage to the product, re-cutting and re-sewing processes, fabric waste, cost increase
7. Button hole Unsuitable position, number or type Damage to the product, re-cutting and re-sewing processes, fabric waste, cost increase
8. Yarn Yarn knitting, knotting or fringing Loss of productivity and quality
9. Seam Fault Seam faults, such as skipping or disassembling Re-sewing, loss of productivity and time
10. Stain Colour changes occurred on the product due to various reasons Loss of productivity and time
11. Cuff form Position, sewing, ironing or size-related defects Labour, time and productivity loss
12. Position Not settling the product pieces at specified lines or levels Labour, time and productivity loss
13. Colour difference Colour mismatch between product parts Productivity loss, re-cutting and re-sewing processes, fabric waste, cost increase
14. Disassembly Stitch defect between parts, button, buttonhole and hemline Labour, time and productivity loss
15. Fibre flies Adhesion of fly fibers on the products Productivity loss
16. Interlining resin traces on fabric surface Non-sticking or -tracing the interlining resin on the fabric surface Labour, time and productivity loss
17. Collar tip form Wrong positioning of the collar and visible seam allowance Productivity loss

Faults and their frequency

Fault Fault quantity Fault percentage (%) Cumulative percentage (%)
1. Collar Tip form 2450 28,21 28,21
2. Stain 2178 25,08 53,29
3. Cuff Form 1128 12,99 66,28
4. Button 870 10,02 76,30
5. Seam Fault 468 5,39 81,69
6. Needle 248 2,86 84,55
7. Color Difference 231 2,66 87,21
8. Position 206 2,37 89,58
9. Interlining Resin 177 2,04 91,62
10. Fiber Flies 152 1,75 93,37
11. Button Hole 113 1,30 94,67
12. Yarn 103 1,19 95,86
13. Size Difference 100 1,15 97,01
14. Fabric Fault 89 1,02 98,03
15. Label 87 1,00 99,03
16. Barcode 45 0,52 99,55
17. Disassembly 40 0,46 100

Comparison of the techniques

Std time-cutting process (sec) Total std time (sec) Price ($)
Manually 14,0 65,2 -
Developed Apparatus 8,3 46,2 84
Automat 7,9 24,6 2050

Records obtained by manual processes

Collar Forming Records
Manually
Taking a piece - putting under the needle Sewing Cutting (the seam allowance) Turn inside out - Forming the edges (manually) (2 Edges) Putting the piece away - taking another one
Sec R Sec R Sec R Sec R Sec R
Sample-1 3,8 100 10,2 100 13 105 30,4 95 1 100
Sample-2 4,2 95 11 95 15 90 31 90 1 100
Sample-3 5 95 10,6 100 14,5 100 29,4 100 2 90
Sample-4 3,66 100 10,8 100 13,4 100 29 100 2,5 90
Sample-5 3 105 12 90 13,9 100 30 100 2 90
Sample-6 3,7 100 10,7 100 14 100 30,7 95 2 90
Sample-7 2,9 110 11 100 14 100 29,8 100 1 100
Sample-8 3,5 100 11 100 13,6 105 30 95 1 100
Sample-9 3,7 100 10,2 100 15 90 32 90 1 100
Sample-10 3,1 100 10 95 14,8 105 29,1 100 1 100
Averages 3,7 100,5 10,8 98,0 14 1 30,1 96,5 1,5 96,0
Basic Time= Avg Time × Avg Rating 100 3,7 10,5 14,0 29,1 1,4
Total Basic Time 58,7
Relaxation Allowance (%4) 2,35
Unavoidable Delays (%7) 4,11
STANDARD TIME (sec) 65,2
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